Timing chain and camshaft sprocket

/ 9-3 (9440) / 2003 / 2. Engine / 4-cylinder petrol / Basic engine / Adjustment/replacement / Timing chain and camshaft sprocket

To remove

1.	Remove the upper engine cover. Detach the battery cable.

2.	Unplug the mass air flow sensor connector and detach the inlet hose from the air cleaner casing cover. Remove the cover and the air filter.

3.	Detach the inlet hose and remove the air cleaner casing. Unplug the connector for the A/C pressure sensor.

4.	Detach the fuel pipe from the snap fastening and remove the fastening bolts from the camshaft cover.

5.	Remove the cover over the ignition coils.

6.	Unplug the ignition coil connectors. Unplug the connectors to the turbo solenoid valve and undo the cable clips.

7.	Remove the bolts, lift up each ignition coil and move aside. Start with the ignition coil for cylinder 1.

8.	Detach the crankcase ventilation hose from the camshaft cover.

9.	Detach and carefully guide the cable duct out of the cylinder head and camshaft cover.

10.	Remove the turbocharger heat shield.

11.	Detach the ground lead from the camshaft cover.

12.	Remove the camshaft cover.

13.	Raise the car and remove the front right wheel.

14.	Remove the right wing liner.

15.	Relieve the belt tensioner using 83 96 095 Belt circuit relieving tool B207 and remove the belt. Mark the direction of rotation of the belt.

16.	Remove the belt tensioner.

17.	Lower the car and zero the engine by turning the crankshaft clockwise until the marking on the crankshaft pulley is aligned with the marking on the timing cover. The cyl. 1 cams on the intake and exhaust camshafts should be pointing up/in.

18.	Remove the chain tensioner. Use 83 96 129 Oil filter tool, B207, and camshaft drive chain tensioner

19.	Remove the lock ring from the chain tensioner and remove the piston.

20.	Fit 83 96 178 Lifting eye kit B207.

21.	Fit 83 94 850 Lifting beam and 83 95 287 Holder . Take the weight off the engine and remove the engine bracket.

22.	Lower the engine about 3 cm using the lifting beam.

23.	Raise the car and remove the crankshaft pulley using 83 95 360 Holding tool, crankshaft pulley (shaft only) and 83 96 210 Holding tool, crankshaft pulley, B207 .

24.	Place a receptacle under the car to collect the oil and carefully remove the timing cover.

25.	Cut away the timing cover gasket around the engine mounting and remove the gasket.

26.	Remove the crankshaft seal. Lower the car.

27.	Remove the plug from the cylinder head.

28.	Remove the upper bolt to the chain guide at the inlet side.

29.	Remove the timing chain upper guide rail.

30.	Remove the lower bolt to the chain guide. Pull the guide down. Detach the lower section of the chain.

31.	Remove the camshaft pinions. Grip the camshaft flats with a spanner when loosening the bolts. Lift the chain.

32.	Remove the tensioner's guide by lifting it up. Check the condition of the guide. Replace if necessary.

To fit

1.	Clean all sealing surfaces.

2.	Clean the camshaft and pinion contact surfaces of oil and grease.

3.	Fit the tensioner's guide.

4.	Set the chain on the input pinion and lower the chain. Fit the pinion on the camshaft and insert the bolt.

5.	Fit the output pinion and insert the bolt.

6.	Raise the car.

7.	Fit the chain on the crankshaft pinion and fit the chain guide.

8.	Lower the car.

9.	Fit the lower bolt. Fit the plug on the cylinder head. Replace the gasket.

10.	Turn the tightening pin clockwise using a screwdriver until it engages in the tensioned position.

11.	Insert the pin in the cavity of the chain tensioner with a new O-ring and fit a new lock ring. Ensure that the lock ring sits correctly in the groove.

12.	Refit the chain tensioner with a new gasket. Tightening torque 75 Nm (55 lbf ft).

13.	Release/activate the chain tensioner by carefully pressing on the transmission chain or chain control (as shown). Use a screwdriver. Check that the tensioner releases.

14.

Remove the exhaust camshaft and intake camshaft bearing caps no. 2 and no. 7. Position 83 96 046 Adjustment tool, camshaft (B207 150-175 hp) and 83 96 079 Adjustment tool, camshaft (B207 200 hp) by manually pressing the tools down onto the camshafts without tightening the bolts. Turn the camshaft until the tool aligns with the spanner on the camshaft flats. Tighten the adjustment tools' bolts. Important When fitting the tools, use the screws accompanying the new tools EN-48366 and EN-48368. Tightening torque 10 Nm (7 lbf ft)

15.	Cut off the part of the gasket that is around the engine mounting and position the new timing cover gasket.

16.	Fit the timing cover. Tightening torque 20 Nm (15 lbf ft).

17.	Position the 83 96 202 Fitting tools, front crankshaft seal B207 protective collar on the crankshaft. Lubricate the new sealing ring with non-acidic Vaseline and position it on the fitting tool.

18.	Position the fitting tool on the crankshaft. Screw in the sealing ring using the crankshaft pulley bolt so that it is flush with the timing cover. Remove the tool.

19.	Fit the crankshaft pulley with a new bolt. Use 83 95 360 Holding tool, crankshaft pulley (shaft only) and 83 96 210 Holding tool, crankshaft pulley, B207 . Tightening torque 100 Nm + 75° (74 lbf ft + 75°)

20.	Check that the markings on the camshaft pulley and timing cover align. Tighten the camshaft pulley once, grip the camshaft flats with a wrench. Tightening torque 30 Nm (22 lbf ft)

21.	Remove the adjustment tools and fit the bearing caps. Tightening torque 8 Nm (6 lbf ft)

22.	Turn the camshaft pulley further to the final point. Grip the camshaft flats with a wrench. Tightening torque 85 Nm + 30° (63 lbf ft +30°)

23.

Turn the camshaft two revolutions in the engine's rotation direction until the marking on the camshaft pulley aligns with the marking on the timing cover. Remove the bearing caps and refit 83 96 046 Adjustment tool, camshaft (B207 150-175 hp) and 83 96 079 Adjustment tool, camshaft (B207 200 hp) in order to check that the camshaft setting is correct. Remove the adjustment tools and fit the bearing caps. Important When fitting the tools, use the screws accompanying the new tools EN-48366 and EN-48368. Tightening torque 8 Nm (6 lbf ft)

24.	Fit the timing chain upper guide rail.

25.	Lower the car and raise the engine with a lifting beam. Fit the engine bracket.

26.	Fit the bolts to the engine bracket. Remove 83 94 850 Lifting beam with holder. Tightening torque 70 Nm + 60° (52 lbf ft + 60°)

27.	Remove 83 96 178 Lifting eye kit B207 .

28.	Fit the camshaft cover with a new seal. Tightening torque 10 Nm (7 lbf ft).

29.	Connect the ground cable to the camshaft cover.

30.	Connect the crankcase ventilation hose to the camshaft cover.

31.	Fit the cable duct and bracket to the camshaft cover.

32.	Fit the ignition coils. Tightening torque 8 Nm (6 lbf ft)

33.	Plug in the ignition coil connectors. Make sure the cables are position correctly so that they are not pinched by the cover. Plug in the connectors to the turbocharger solenoid valve and attach the cable clips.

34.	Fit the cover over the ignition coils.

35.	Press the fuel lines and ventilation lines into the clips on the camshaft cover. Connect the quick-release coupling for the ventilation line.

36.	Connect both fuel lines to the fuel rail while gripping the lower nut. Use new seals. Tightening torque 10 Nm (7 lbf ft).

37.	Fit the turbocharger heat shield.

38.	Fit the air cleaner casing and connect the intake hose. Plug in the A/C pressure sensor connector.

39.	Fit the filter element and the air cleaner casing cover. Connect the inlet hose and the mass air flow sensor connector.

40.	Fit the upper engine cover.

41.	Raise the car and fit the belt tensioner. Tightening torque 50 Nm (37 lbf ft)

42.	Relieve the belt tensioner with 83 96 095 Belt circuit relieving tool B207 and fit the belt in the marked direction of rotation. Make sure the belt is located correctly on all the pulleys.

43.	Lower the car slightly and fit the right wing liner.

44.	Fit the front right wheel. See Wheels.

45.	Lower the car to the floor.

46.	Check the engine oil level. Top up as necessary. Connect the battery cable.

47.	Carry out Procedures after reconnecting the battery .

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